Product comprising product sub-parts connected to each other by a crimp connection

ABSTRACT

In the case of a product ( 1 ) having a first product sub-part ( 4 ) and a second product sub-part ( 3 ), the two product sub-parts ( 3, 4 ) each comprise two connection zones ( 8, 9, 10, 11 ) consisting of metal and of suitably thin construction for a crimping process and the connection zones ( 8, 9, 10, 11 ) are connected together in pairs by means in each case of a crimp connection, in which the connection zones ( 10, 11 ) of at least one product sub-part ( 3 ) exhibit the remnants ( 16 ), remaining after performance of the crimping process, of elevations ( 17 ) present prior to performance of the crimping process.

[0001] The invention relates to a product having a first productsub-part and a second product sub-part, which two product sub-parts eachconsist of metal and each comprise a connection zone of suitably thinconstruction for a crimping process, which connection zones areconnected together by means of a crimp connection.

[0002] Such a product has been sold commercially in the form of anelectronic article surveillance label (EAS label) and is thereforeknown. With the known label, a backing film is accommodated between twoprotective layers consisting of paper, in which a transmission coilformed of etched or printed conductive tracks is provided on one mainface of the backing film and in which, on the other main face of thebacking film, there is provided a foil-type metal bridge serving tobridge the conductive tracks of the transmission coil and in which thetransmission coil constitutes a first product sub-part and the metalbridge constitutes a second product sub-part. Furthermore, thetransmission coil is provided with two connection zones, each of whichis connected, through the backing film, with a counter-connection zoneof the metal bridge by means in each case of a crimp connection. In theknown configuration, the connection zones of the transmission coil andthe counter-connection zones of the metal bridge are each of flatconstruction, which entails the problem that mechanical connection andalso electrical connection of the connection zones of the transmissioncoil and the counter-connection zones of the metal bridge cannot alwaysbe perfectly achieved by the crimping process performed to produce therespective crimp connection, such that crimp connections which aredefect-free and operational do not always exist.

[0003] It is an object of the invention to eliminate the above-describedshortcomings and to provide an improved product.

[0004] To achieve the above-mentioned object, features according to theinvention are provided for a product according to the invention, suchthat a product according to the invention may be characterized in thefollowing way, namely:

[0005] A product having a first product sub-part and having a secondproduct sub-part, in which the first product sub-part comprises aconnection zone consisting of metal and of suitably thin constructionfor a crimping process and in which the second product sub-partcomprises a counter-connection zone consisting of metal and of suitablythin construction for a crimping process and in which the connectionzone and the counter-connection zone are connected together by means ofa crimp connection formed by the performance of a crimping process andin which, of the connection zone and the counter-connection zone, atleast one of these two connection zones comprises the remnants,remaining after the performance of the crimping process, of elevationspresent prior to the performance of the crimping process, which remnantslie between the two connection zones.

[0006] By providing the features according to the invention, it isensured in a structurally simple and additionally also simply produciblemanner that, during production of the product and in particular duringproduction of the crimp connection between the connection zones to beconnected together, precisely defined contact areas arise between theconnection zones to be connected by means of the elevations provided inthe case of at least one connection zone, which has the consequence thatthe energy applied to produce the crimp connections by means of acrimping device is introduced in concentrated manner in the contactareas, which results altogether in a crimp connection between twoconnection zones which displays high connection reliability, in whichthe high connection reliability is true both of the mechanicalconnection and of the electrical connection between two connectionzones.

[0007] In the case of a product according to the invention, theformation of a crimp connection between two connection zones isperformed for example by means of a crimping device by the applicationof mechanical pressure and additionally of ultrasound, in which as aconsequence of the application of ultrasound a weld joint is then formedbetween the two connection zones consisting of metal. However, it hasalso proven very advantageous for a connection means suited to assistingthe mechanical connection between the two connection zones isadditionally provided between the connection zone and thecounter-connection zone. In this way, the advantage is achieved that acrimp connection may be achieved purely through the application ofpressure by means of a crimping device.

[0008] In the case of a product as described above, the additionalconnection means may comprise for example an initially pasty or more orless liquid adhesive. However, it has proven particularly advantageousfor the connection means to comprise a film consisting of plastics andsoftenable at least once by heating and for the remnants to be pressedthrough the film. Such a configuration is distinguished above all byvery great simplicity of production. Moreover, this configurationprovides the advantage that a film of plastics provided anyway betweentwo connection zones in the case of certain products is at the same timeexploited as an additional connection means for assisting the mechanicalstrength of a crimp connection, in which an adhesive action andconsequently an adhesive connection is achieved by means of thesoftenable and thereby fusible film.

[0009] In the case of a product according to the invention, it hasproven particularly advantageous for the product to take the form of atransponder for contactless communication with a communications station.Such a configuration has proven particularly favorable in practice.

[0010] The invention further relates to a starting product for a productsub-part, which starting product is intended for production in a productand for use in such a product. Such a starting product according to theinvention comprises features according to the invention, such that astarting product according to the invention may be characterized in thefollowing way, namely:

[0011] A starting product for a product sub-part, which starting productis provided for use in a product and which starting product comprises acounter-connection zone which consists of metal and is of suitably thinconstruction for a crimping process, in which the counter-connectionzone is provided with elevations, which elevations are provided to bepressed against a connection zone during production of a crimpconnection.

[0012] By providing the features according to the invention, a startingproduct is obtained in a structurally simple and simply produciblemanner for a product sub-part or for a product, with which a crimpconnection may be obtained which is reliable and long-lasting from boththe mechanical and the electrical standpoint.

[0013] In the case of a starting product according to the invention, ithas proven particularly advantageous for the elevations to be formed byan embossing process. Such an embossing process is particularlyadvantageously suitable for producing such elevations in the case of astarting product according to the invention, because with such anembossing process the height in particular, but also other dimensions ofthe elevations, may be produced in a precise and precisely reproduciblemanner. This is important because the dimensions of the elevations andadditionally also the positions and density of the elevations have asubstantial influence on the positive effects of the elevations informing and maintaining a crimp connection.

[0014] The above-stated aspects of the invention and further aspectsthereof emerge from the examples of embodiment described below and areexplained with reference to these examples of embodiment.

[0015] The invention will be further described with reference to twoexamples of embodiment shown in the drawings, to which, however, theinvention is not restricted.

[0016]FIG. 1 shows schematically, in a view from above, a productaccording to one example of embodiment of the invention in the form of aso-called inlet, in which a bridge part is provided.

[0017]FIG. 2 is a sectional view along line II-II of FIG. 1 of a detailof the inlet according to FIG. 1.

[0018]FIG. 3 is an oblique view of a portion of a starting product forthe bridge part of the inlet according to FIG. 1.

[0019]FIG. 4 shows, analogously to FIG. 1, part of a further inletconstituting a product according to a second example of embodiment ofthe invention.

[0020]FIG. 1 shows a product 1 according to the invention, this product1 being a so-called inlet 1, which is provided to produce a transponderfor contactless communication with a communications station. Duringproduction of such a transponder, the inlet 1 is embedded in atransponder body, in which the embedding may be performed by alaminating process or an injection molding process or indeed by anadhesion process and the transponder body may accordingly consist ofplastics or of bonded layers of paper. Thus, not only does the inlet 1constitute a product according to the invention but also a transponderproduced with this inlet 1 and not shown constitutes such a productaccording to the invention.

[0021] The inlet 1 comprises a first product sub-part 2, namely a film2, and a second product sub-part 3, namely a bridge part 3. Thefunctionality of the bridge part 3 is examined in more detail below. Thefilm 2 serves as support for a transmission coil 4, which is provided inthe present case on the top of the film 2 and which consists of aplurality of windings, in which only three windings 5, 6 and 7 in totalare shown in FIG. 1 for the sake of clarity. The transmission coil 4 andits windings 5, 6 and 7 are produced in the present case by means of aprinting process. However, they may be produced in other ways, forexample by means of an etching process or other production processesknown in this context. The transmission coil 4 and thus its windings 5,6 and 7 consist of metal, namely of copper. The free end of the outerwinding 5 develops into a first connection zone 8, which is in this casesubstantially circular. The free end of the inner winding 7 developsinto a second connection zone 9, which is in this case likewisesubstantially circular. The two connection zones 8 and 9 have beenproduced in the course of and at the same time as production of thetransmission coil 4 and therefore likewise consist of metal, namely ofcopper, and are of suitably thin construction for a crimping process.

[0022] To render the transmission coil 4 functional, the two connectionzones 8 and 9 have to be connected together electrically. For thispurpose, the bridge part 3 is provided, which, in contrast to thetransmission coil 4, which in the present case is provided on the top ofthe film 2, is located on the underside of the film 2, as is clear fromFIG. 2. The bridge part 3 comprises a first counter-connection zone 10and a second counter-connection zone 11. The two counter-connectionzones 10 and 11 of the bridge part 3 here likewise consist of metal,namely of a copper-tin alloy, and are likewise of suitably thinconstruction for a crimping process. The two connection zones 8 and 9 ofthe transmission coil 4 and the two counter-connection zones 10 and 11of the bridge part 3 are in each case connected together by means of acrimp connection formed by the performance of a crimping process. In thecase of the inlet 1 according to FIG. 1, to produce the two crimpconnections use was made of a crimping tool with two tool partsexhibiting high surface roughness and capable of being pressed together,which is clear from the fact that notch-like or wedge-like recesses 12,13, 14 and 15 are present in the area of the free boundary surfaces ofthe four connection zones 8, 9, 10 and 11.

[0023] In the case of the inlet 1, it is advantageously particularly thecase that the two counter-connection zones 10 and 11 of the bridge part3 comprise the remnants 16, remaining after the performance of thecrimping process, of elevations 17 present prior to the performance ofthe crimping process, which remnants 16 lie between thecounter-connection zones 10 and 11 displaying the remnants 16 and theother connection zones 8 and 9.

[0024] In the case of the inlet 1 according to FIGS. 1 and 2, there isadditionally provided between each connection zone 8 or 9 and therespective opposing counter-connection zone 10 or 11 a connection means(connection agent) suited to assisting the mechanical crimp connectionbetween the two pairs of connection zones 8, 10 and 9, 11, in which theconnection means comprises the film 2 consisting of plastics andsoftenable once by heating and in which the remnants 16 are pressedthrough the film 2. A repeatedly softenable film may also be provided,or indeed an insulating material, which allows throughplating due to itsresilience. During production of the crimp connections between theconnection zones 8, 10 and 9, 11 respectively, not only is mechanicalpressure applied by means of the above-mentioned crimping tool, butadditionally also heat, which has the consequence of heating and therebyfusing the film 2, which has the consequence that, by means of the film2, an adhesive effect arises between the film 2 and the portions of thetransmission coil 4 and the bridge part 3 adjoining the film 2, suchthat adhesive connections thus additionally arise in the area of thecrimp connections, which provide marked assistance to the mechanicalcrimp connections between the two connection zones 8 and 9 of thetransmission coil 4 and the two counter-connection zones 10 and 11 ofthe bridge part 3.

[0025] As mentioned above, remnants 16 of elevations 17 are provided inthe case of the inlet 1 according to FIGS. 1 and 2. In this respect,reference is made to FIG. 3. FIG. 3 shows part of a starting product 18for the bridge part 3, which starting product 18 is provided for usewith an inlet, such as the inlet 1 according to FIGS. 1 and 2. Thestarting product 18 comprises the two counter-connection zones 10 and11, of which FIG. 3 shows only the second counter-connection zone 11,however. The two counter-connection zones 10 and 11 of the startingproduct 18 are made of metal, as is the entire starting product 18,namely of a copper-tin alloy, and the counter-connection zones 10 and 11are moreover of suitably thin construction for a crimping process.

[0026] As is clear from FIG. 3, each counter-connection zone 10 or 11 isprovided with elevations 17, which elevations 17 are provided forpressing against a connection zone 8 or 9 respectively during productionof a crimp connection. The elevations 17 were here formed in aparticularly simple, advantageous way by an embossing process. In thepresent case, the elevations 17 are trough-shaped bulges. It goeswithout saying that other configurations and shapes are also possible,for example dome-shaped elevations. When performing a crimping processfor producing the product according to FIGS. 1 and 2, in which crimpingprocess both mechanical pressure and heat are applied by means of acrimping tool, the elevations 17 are pressed against the connectionzones 8 and 9 of the transmission coil 4, in which the elevations 17pass through the heated film 2 and are additionally markedly reduced inheight until the remnants 16 of the elevations 17 are obtained.

[0027] The advantage of providing the elevations 17 lies in particularin that precisely defined contact areas or active areas are obtained bymeans of the elevations 17 between the connection zones 8 and 9 of thetransmission coil 4 and the counter-connection zones 10 and 11 of thebridge part 3, whereby a defect-free electrical connection is achievedhighly reliably between the connection zones 8 and 9 of the transmissioncoil 4 and the counter-connection zones 10 and 11 of the bridge part 3.In addition, the elevations 17 also offer the advantage that, during theapplication of mechanical pressure by means of the crimping tool, theenergy introduced acts in a concentrated manner, which also provesadvantageous with regard to the mechanical strength of the crimpconnections produced.

[0028] With respect to the inlet 1 according to FIG. 1, it should alsobe mentioned that, in the case of this inlet 1, the internal winding 7is of interrupted construction and comprises a first terminal lug 19 anda second terminal lug 20 in the area of its interruption. Between thetwo terminal lugs 19 and 20 there is provided a chip 21, which isprovided with two terminals, namely with two so-called bumps 22 and 23,and which, in so-called flip-chip technology, is connected inelectrically conductive manner to the two terminal lugs 19 and 20 bymeans of its bumps 22 and 23, in which the chip 21 is additionallyconnected mechanically to the film 2 by means of an adhesive connection,not shown in FIG. 1.

[0029]FIG. 4 shows a further inlet 1, but only in part. In the case ofthis inlet 1, the transmission coil 4 is located on the underside of thefilm 2. A unit 24 is provided on the top of the film 2, which unitconsists of a chip 25 and two terminal lugs 26 and 27. The chip 25comprises two bumps 28 and 29 and is connected, in so-called flip-chiptechnology, in electrically conductive manner to the terminal lugs 26and 27 by means of its two bumps 28 and 29, in which a mechanicalconnection, not described in any more detail, is additionally alsoprovided. The two terminal lugs 26 and 27 consist of metal, namely of acopper-tin alloy, and are of suitably thin construction for a crimpingprocess. The terminal lug 26 comprises a counter-connection zone 30. Theterminal lug 27 comprises a counter-connection zone 31. Thecounter-connection zone 30 is connected, as with the inlet 1 accordingto FIGS. 1 and 2, through the film 2 with the first connection zone 8 ofthe transmission coil 4. The second counter-connection zone 31 isconnected through the film 2 with the second connection zone 9 of thetransmission coil 4 by means of a crimp connection. In the case of theinlet 1, the unit 24 constitutes a second product sub-part, whichcomprises counter-connection zones 30 and 31, in which thecounter-connection zones 30 and 31 exhibit the remnants, remaining afterthe performance of the crimping process, of elevations present prior tothe performance of the crimping process; this is not shown in separatedetail for the inlet 1 according to FIG. 4, however.

[0030] It may be mentioned that the counter-connection zones 10 and 11may also consist of tin or gold or silver or also of ductile materialshaving a coating of the above-mentioned metals and copper.

[0031] The invention is not limited to the products described here, butrather relates to all products in which a crimp connection is providedbetween two product sub-parts.

1. A product (1) having a first product sub-part (4) and having a secondproduct sub-part (3; 24), in which the first product sub-part (4)comprises a connection zone (8, 9) consisting of metal and of suitablythin construction for a crimping process and in which the second productsub-part (3; 24) comprises a counter-connection zone (10, 11; 30, 31)consisting of metal and of suitably thin construction for a crimpingprocess and in which the connection zone (8, 9) and thecounter-connection zone (10, 11; 30, 31) are connected together by meansof a crimp connection formed by the performance of a crimping processand in which, of the connection zone (8, 9) and the counter-connectionzone (10, 11; 30, 31), at least one (10, 11; 30,31) of these twoconnections zones (8, 9, 10, 11; 30, 31) comprises the remnants (16),remaining after the performance of the crimping process, of elevations(17) present prior to the performance of the crimping process, whichremnants (16) lie between the two connection zones (8,9, 10, 11; 30,31).2. A product (1) as claimed in claim 1, in which a connection means (2)suited to assisting the mechanical connection between the two connectionzones (8, 9, 10, 11) is additionally provided between the connectionzone (8, 9) and the counter-connection zone (10, 11).
 3. A product (1)as claimed in claim 2, in which the connection means (2) comprises afilm (2) consisting of plastics and softenable at least once by heatingand in which the remnants (16) are pressed through the film (2).
 4. Aproduct (1) as claimed in claim 1, in which the product (1) takes theform of a transponder for contactless communication with acommunications station.
 5. A starting product (18) for a productsub-part (3; 24), which starting product (18) is provided for use in aproduct (1) and which starting product (18) comprises acounter-connection zone (10, 11; 30, 31) which consists of metal and isof suitably thin construction for a crimping process, in which thecounter-connection zone (10, 11; 30, 31) is provided with elevations(17), which elevations (17) are provided for pressing against aconnection zone (8, 9) during production of a crimp connection.
 6. Astarting product (18) as claimed in claim 5, in which the elevations(17) are formed by an embossing process.